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Keston K170, Installation And Servicing Instructions

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Keston K170 Installation And Servicing Instructions Download Page 35

5.6

ILLUSTRATED WIRING DIAGRAM

WD51/2/1997   Chapter 5 : Fault FindingThe Keston 170 Condensing Boiler

Installation & Servicing Instructions

Page  :  32

ILLUSTRATED WIRING DIAGRAM

RAM
Control

Flow Overheat Stat   

Flow High
Limit Stat

Boiler Stat

Air Pressure Switch

Gas Valve

Flue Overheat Stat

Ignition Electrode

Low Water Pressure Switch Gas Low 

Pressure Switch

Relay

Blower

7W

51PK

52BK

93OR

92OR

11W

55BR

10BK

G/Y

8W

W

6BR

5BR

N

SL

53

W

54

G

91O

R

95G

93R

5R

12

V

90R

ON/OFF

SWITCH

9G

Lockout

Lamp

Run

Lamp

FILTER

1

2

3

4

5

6

7

9

10

8

6BR

12B

BR

B

Thermal Fuse

56R

1

2

3

4

5

6

7

8

9

10

11

12

G/Y

G/

Y

G/Y

5R

8W

8W

BR

B

59

P

K

10BK

91

OR

7W

PL

room

stat

(

)

15
14

13

PUMP

L

N

6B

4B

3BR

Summary of Contents for K170

Page 1: ...ation And Servicing Instructions Keston 170 GC No 41 930 04 CE No 87AR50 These instructions must be left either with the user or next to the site gas meter 34 West Common Road Hayes Bromley Kent BR2 7...

Page 2: ...ge 2 12 Radiant Floor Heating 2 13 Low Water Volume Boiler vs Cast Iron Boiler 2 14 Determine Radiation Needed Room By Room 3 INSTALLATION OF THE BOILER 3 1 Wall Mounting Bracket 3 2 Mounting The Boil...

Page 3: ...fice 8 SPARE PARTS LISTINGS BENCHMARK INITIATIVE As part of the industry wide Benchmark Initiative all Keston 170 boilers now include a Benchmark Installation Commissioning and Service Record Log Book...

Page 4: ...istics of the boiler coil must be taken into consideration when calculating the pump size The Keston boiler is not a high water content boiler and does not contain the metal mass or water volume of a...

Page 5: ...ature of the flue gases are usually around 10o C above the temperature of the return water The flue pipe should be terminated outside the building from where they cannot re enter the building or any o...

Page 6: ...er kW 54 5 50o C Flow 30o C Return Btu h 186 000 Burner Setting Pressure mbar 10 0 Hot in wg 3 94 Gas Comsumption After l s 1 42 10 mins Running Ft3 hr 180 73 CV of Gas 38 7 MJ m3 1038 Btu Ft3 Max Ope...

Page 7: ...s of the current IEE Wiring Regulations and in Scotland the electrical provisions of the Building Regulations applicable in Scotland with respect to the installation of the boiler in a room or interna...

Page 8: ...let NB Refer to Section 2 8 3 The Keston can be located virtually anywhere desired provided that all regulations are complied with Because of the boiler s compact size and venting flexibility the inst...

Page 9: ...he service pipe by the local gas region or their contractor An existing meter should be checked preferably by the gas region to ensure that the meter is adequate to deal with the rate of gas supply re...

Page 10: ...ry threaded or compression fittings Pipes should have a gradient to ensure air is passed easily to vent points and water flows readily to drain points j Draining taps must be located in accessible pos...

Page 11: ...449 and BS 7074 Pt 1 The vessel must be positioned on the inlet to the pump iii A filling point in accordance with local water authority requirements iv A method of system make up automatic or manual...

Page 12: ...g Insufficient water flows through the boiler will cause the boiler to kettle or even produce steam which can damage the heat exchanger and will invalidate the heat exchanger warranty It is normally...

Page 13: ...e to debris abrasion within the system 2 7 7 Pump Selection The Keston boilers have low water content heat exchangers with a high resistance to flow when compared with cast iron heat exchanger boilers...

Page 14: ...ed and are illustrated in Figure 2 8 1 above 2 8 2 Maximum Lengths The maximum lengths of both air inlet pipe and flue outlet pipe when no bends are used are as detailed below Maximum Air Inlet Length...

Page 15: ...ections in excess of 2m These additional condensate drains must be run to discharge as detailed in section 2 11 Such drain points can be formed using standard muPVC fittings Refer to the example in Fi...

Page 16: ...2 8 5 Clearances From Wall Flue outlet and air inlet terminations must be at least 60 mm and 95 mm respectively from the wall face 2 8 6 Distance Between Flue Outlet Air Inlet There is no maximum the...

Page 17: ...s outside the property must be at least 32 mm inside diameter 2 12 RADIANT FLOOR HEATING The low operating temperatures of this type of system lead to very good operating efficiencies In fact under fl...

Page 18: ...the boiler or short cycling will occur Likewise pumping rates of water through low water volume boilers must be maintained so that water is moved through the boiler fast enough so as not to reach boi...

Page 19: ...ing screws of an appropriate size for the wall type No 12 x 2 inch wood screws normally suffice f Mark the bottom fixing hole and drill for a No 8 x 1 inch wood screw Insert plug 3 2 MOUNTING THE BOIL...

Page 20: ...enter the appliance or the plastic pipework b Drill the two holes in the wall ceiling preferably using a core drill 3 4 1 Diameter of holes i Allowance must be made for socketed lengths if these are...

Page 21: ...pipework f From outside complete the two terminations See Section 2 8 Flue System and make good all holes g Support any pipes whose route could be displaced either of its own accord or by accident Any...

Page 22: ...ttom right of the cabinet 1 The electrical supply must be as specified in Chapter 2 Section 2 4 Electrical Supply WARNING THIS APPLIANCE MUST BE EARTHED 2 All external controls and wiring must be suit...

Page 23: ...complete gas installation up to the boiler service cock must be checked for soundness BS 6891 Electrical Installation Carry out preliminary electrical safety checks i e Earth continuity Polarity Resis...

Page 24: ...n 2 7 Water Systems At this stage for sealed systems fill to a pressure of about 2 7 bar d Check the complete system for water soundness If leaks need to be rectified using flux and solder the system...

Page 25: ...gests that there is a possible restriction in the flue outlet pipework Note the exact reading h Turn the gas service cock to ON i Turn off the electricity supply wait 10 seconds and turn back on The b...

Page 26: ...t cap to cover the burner pressure adjustment screw 4 8 TIMING THE GAS METER NATURAL GAS After the boiler has been started and with no other appliances using gas time the gas meter to be certain that...

Page 27: ...is present for proper and complete combustion 4 10 HANDING OVER TO THE USER It is important to fully explain the following a Procedure to light and turn off the boiler including isolation of the elect...

Page 28: ...r is interrupted to the boiler by any external control or the boiler thermostat If an interruption to the gas supply causes loss of the flame the control box will pause for approximately 10 seconds an...

Page 29: ...uck in the NO position Is there 230V between control box pins 6 neutral Is there continuity between live supply from relay to blower Neutral through motor resistance Is the fan running Is motor overlo...

Page 30: ...than 4 in water Is the air filter dirty or the air inlet exhaust or condensate pipe blocked Is the Burner blocked Fan faulty change Is the gas flow rate to the boiler correct for the gas type in use i...

Page 31: ...alve Replace Faulty Gas Low Pressure Switch Replace Is there a spark present Is the HT voltage present at top of ignition electrode Is the spark gap 4 mm Faulty Conrtrol Box Replace Replace Adjust Spa...

Page 32: ...n therm ostat both term inals Check external controls Faulty sw itch Replace Thermostat tripped reset OR faulty therm ostat Replace High cabinet tem perature check all joints for products leakage Repl...

Page 33: ...FUNCTIONAL FLOW WIRING DIAGRAM WD51 2 1997 Chapter 5 Fault FindingThe Keston 170 Condensing Boiler Installation Servicing Instructions Page 30 N EMC Filter 2 5 10 8 1 4 6 EMC Filter SL PL Pump L Pump...

Page 34: ...FLOW HIGH LIMIT THERMOSTAT FLOW OVERHEAT THERMOSTAT APS GAS VALVE HV BOILER THERMOSTAT THERMAL FUSE EMC GAS LOW PRESSURE SWITCH m p RED LAMP no nc N 13 14 15 1 2 3 4 6 7 8 N L LEGEND Y G GREEN YELLOW...

Page 35: ...t Air Pressure Switch Gas Valve Flue Overheat Stat Ignition Electrode Low Water Pressure Switch Gas Low Pressure Switch Relay Blower 7W 51PK 52BK 93OR 92OR 11W 55BR 10BK G Y 8W W 6BR 5BR N SL 53W 54G...

Page 36: ...7 17 4 10 00 0 HARNESS PACTROL RAM 144 SUPRESSOR FILTER MAINS 04 4 02 00 0 SECTION 1 13 13 8 SECTION 1 RELAY SOCKET 17 4 04 00 0 RELAY 17 4 03 00 0 RELAY CLAMP 17 4 00 02 0 124 123 105 125 17 4 00 01...

Page 37: ...45 17 2 04 00 0 BURNER LABEL 04 2 00 58 0 HIGH VOLTAGE 44 17 2 03 00 1 43 HEAT EXCHANGER INSULATION 17 2 01 00 2 HEAT EXCHANGER 42 04 2 17 00 0 THERMOSTAT WATER RETURN 63 TRAP HOSE CONDENSATE 04 2 00...

Page 38: ...SKET 102 GASKET 104 17 2 00 05 0 17 3 02 00 0 79 CAPACITOR BLOWER 78 17 3 01 00 0 80 04 3 04 00 0 BLOWER RUBBER ISOLATOR 1 SECTION 1 AIR HOSE CLAMP 17 3 00 07 0 92 17 3 00 02 0 AIR INLET FLEX CONNECTO...

Page 39: ...0 60 0 FLAME LABEL 14 DEVICE BOX 17 1 00 19 0 3 10 17 1 00 29 1 SWITCH FIXING NUT 17 1 00 32 0 62 35 04 1 16 00 0 WIRE RETAINER ELECTRIC MAIN 66 04 1 00 75 0 PLASTIC PLUG 22 04 1 00 49 0 22mm GROMMET...

Page 40: ...ap 375 530 63 Boiler Thermostat 375 532 67 Flue Overheat Thermostat 114 043 69 Combustion Test Plug 375 533 71 Flow Overheat Thermostat 375 534 72 Flow High Limit Thermostat 114 045 73 Water Pressure...

Page 41: ...for leakage of gas gas air or combustion products d Check for condensate leaks e Check the colour and appearance of the flame A sky blue flame slightly off the burner gauze is normal The burner itsel...

Page 42: ...rty remove the dirt with a vacuum cleaner or by other means If in any doubt renew the filter element b Remove the burner head Section 7 7 and inspect the burner appearance Black markings or other disc...

Page 43: ...air supply joint is air tight h Turn on the electrical supply to the boiler and allow the boiler to reach operating temperature levels i Visually inspect the burner through the glass spy hole at the b...

Page 44: ...IGNITION CONTROL BOX 7 4 7 AIR PRESSURE SWITCH 7 4 8 COMBUSTION BLOWER 7 4 9 GAS CONTROL VALVE 7 4 10 GAS LOW PRESSURE SWITCH 7 5 GAS ORIFICE 7 6 SPARK IGNITION FLAME DETECTION ELECTRODE 7 7 BURNER HE...

Page 45: ...ng This is secured by three press studs on either side and a central press stud at the bottom of the control panel 7 3 REPLACEMENT PROCEDURES i Always replace in the reverse order unless otherwise sta...

Page 46: ...O ring between thermostat and flue pipe If this is damaged on removal it must be replaced vi Reassemble Section 7 3 NB When fitting the new thermostat it is an advantage to smear a thin film of heat...

Page 47: ...the cabinet vi Reassemble Section 7 3 NB When reassembling inspect any gaskets for damage and replace if necessary vii Reset the gas rate See Section 4 Commissioning 7 4 9 Gas Control Valve Fig 5 7 3...

Page 48: ...e and replace if necessary With the new spark ignition electrode in place it is essential to ensure the gap between the tip of the electrode and the burner surface is 4 mm Distance above or below 4 mm...

Page 49: ...changer to its mounting bracket xviii Remove the heat exchanger with pipework attached xix Remove the flow return and flue pipework from the heat exchanger Replacement heat exchangers are supplied wit...

Page 50: ...ner head iv Reassemble Section 7 3 7 13 HT IGNITION LEAD Fig 5 7 1 item 122 i Isolate the appliance Section 7 1 ii Gain access Section 7 2 iii Remove the lead from the electrode and the ignition contr...

Page 51: ...nifold Gasket 49 375 527Ignitor Gasket 50 114 120Ignitor Sensor Probe 55 114 122Flexible Hose Gasket 63 375 530Boiler Thermostat 67 375 532Flue Thermostat 71 375 533Flow Overheat Thermostat 72 375 534...

Page 52: ...utlet Gasket 104 114 122Flexible Hose Gasket 91 375 536Gas Valve 106 E01 074 Ignition Control Box 109 170 084Air Pressure Switch 122 E01 075 HT Ignition Cable WD51 2 1997 Chapter 8 Spare Parts Listing...

Page 53: ...Flexible Hose Gasket 63 375 530 Boiler Thermostat 67 375 532 Flue Thermostat 71 375 533 Flow Overheat Thermostat 72 375 534 Flow High Limit Thermostat 90 114 139 Gas Valve Gasket 91 375 536 Gas Multif...

Page 54: ...ensure that no damage is done to the internal pipework Ensure that the 22mm condensate pipe is not exposed to freezing conditions Make sure that the exhaust pipe terminates away from windows or vents...

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